Building construction



Sept. 6, 1938. H. G. HAUcH BUILDING CONSTRUCTION Filed May 29, 1937 3 Sheets-Sheet l .IV v,

ATTORNEY Sept. 6, 1938. H, HAU'CH' 2,129,423

- BUILDING CONSTRUCTION Filed-May 29, 1957 3 Sheets-Sheet 2 INVENTOR. Hen/*g 6*. #duc/7 ATTORNEY.

Sept. 6, 1938. H, G. HAUCH 2,129,423

BUILDING CONSTRUCTION Filed May29, 1937 3 Sheets-Sheet 5 ATTORNEY.

Patented Sept. 6, 1938 UNITED STATES PATENT OFFICE BUILDING CONSTRUCTION Henry G. Hauch, Oakland, Calif., assigner to My invention relates to means for utilizing enameled metal sheets in constructing buildings and particularly for finishing the exposed exterior and interior surfaces thereof.

Enameled metal sheets are well known for various purposes and have been utilized from time to time in building construction, but certain difficulties present themselves since the metal on which the enamel is placed is usually subject to attack by the Weather; the finis-hed enameled, sheets because of the high temperature of the enameling process are not planar but present undulatory or wavy surfaces which sometimes produce undesirable architectural effects; and the sheets are often diiiicult to ship, handle and install because of danger of chipping the enamel, because they cannot ordinarily be readily worked on the site of the building operation, and particularly because they are diliicult to fasten in relatively small sections over an extensive area.

An object of my invention is to overcome all of the difculties mentioned heretofore.

Another object of my invention is in general to provide a building construction in which enameled metal sheets can suitably be utilized.

A further object of my invention is to provide an economical and readily feasible manner of providing metal enamel sheets for building construction.

ing unit of my invention.

Fig. 3 is an elevation, portions being broken away, of a fragment of a building construction in accordance with my invention.

Fig. 4 is a cross-section similar to Fig. 1, but showing a modified building construction in accordance with my invention.

Fig. 5 is a View similar to Fig. l, but showing a further modified form of building construction in accordance with my invention.

Fig. 6 is an elevation of a further modified form of building construction in accordance with my invention.

Ferro Enameling Company, Oakland, Calif., a co-partnership consisting of Howard L. Brooks and Harold B. Naylor Application May 29, 1937, Serial No. 145,477"

Fig. 7' is a cross-section the plane of which is indicated by the line 1-1 of Fig. 6.

Fig. 8 is a cross-section the plane of which is indicated by the line B-B of Fig. 6.

Fig. 9 is a cross-section comparable to Fig. l, but showing a modified form of fastening.

Fig. l0 is on the left side an elevation and on the right side a cross-section, of an additionally modified form of building construction unit in accordance with my invention.

Fig. 1l is an end elevation of the unit shown in Fig. 10.

Fig. l2 is a cross-section on a vertical plane, showing a building construction incorporating the unit of Figs. 10 and l1.

In its preferred form, the building construction of my invention includes a suitable supporting structure to which is fastened a building unit comprised of a sheet of thermal insulating material to which a sheet of enameled metal is secured, the fastening means for the building unit being preferably such as to be readily applied by workmen on the construction job, and being such as to interlock marginally with the building units.

As an example, the building construction of my invention is applied to a support 6, such as an upright stud in the wall of a building, for illustration, to the exterior surface 'l thereof. `To the support 6 I preferably secure the lower one 8 of a building unit which is comprised of a sheet 9 of insulating material, preferably thermal :insulating material, of compressed fibre suitably treated for resistance to disintegration and forming a relatively dense, compact mass.

5 Claims.

tangular contour, although not necessarily so, I preferably afx a sheet ll which is of. relatively thin metal, usually a ferrous metal, to the eX- posed surface I2v of which, particularly, has been applied an enamel, usually a glass enamel.

The preparation of the enameled sheet Il is standard'and results usually in the production of a relatively undulatory, uneven, partially reflecting surface. The sheet ll is quite durable, except possibly for the marginal edges I3 thereof where the metal may not be well protected. In producing the building unit of my invention, I preferably fabricate an enameled sheet Il of similar shape to that of the insulating sheet 9 but of slightly smaller dimensions so that the sheet 9 projects slightly, as at I4, from the boundaries of the metal sheet ll. When the sheets are vbrought into superposition, I preferably interposean adhesive layer I6 therebetween, such as a layer of glue or cement, and then com- To the sheet 9, which is generally cut to a recpress the sheets together in a press, such as a veneer press.

The pressure exerted is in no wise detrimental to the enameled surface of the sheet II, but is effective not only to provide a verylclose adherence between the metal sheet I I and the insulating sheet 9 but also to compress the material of the sheet 9 somewhat to make it thinner than it originally was and to make it considerably stiffer and more rigid. At the same time the undulatory and uneven supercial characteristics of the sheet II are reduced, so that the sheet is relatively smooth and planar and so that light is reflected from it without material distortion. There thus results a considerably improved sheet of metal enamel, amply backed by a thermal insulating layer, so that the composite unit is effective to resist virtually all of. the elements.

As a final step in the preparation of the composite unit, I preferably bound the margin of the sheet 9 with an edge which is nonplanar in crosssection-for instance, by rabbeting or cutting a groove I1 which extends for substantially the full thickness of the compressed sheet 9 but which still leaves the projection I4 so that when the units are shipped or otherwise handled, the edges of the sheet II are mechanically protected.

The grooved, composite unit is assembled by being placed against the support 6, and a wooden strip I9 is placed within the groove I1, making a reasonably accurate t therewith. The strip I9 is usually referred to as sticker stock and is a relatively standard commodity but p-referably is treated with a preservative, such as creosote. It can be separately handled from the composite unit or can be temporarily mounted in place on one of the sheets 9 by a nail 2I fastening it in place; but preferably the strip I9 is considerably longer than the length of one of the composite building units, so that it is placed in position after one of the units or a plurality of the units are held against the stud 6.

The strip I9 is held in place against the stud 6 and simultaneously holds the panel or unit 9 in position by a nail 22 which is driven in at an angle such as to force the strip and composite building unit against the stud 6 in a downward and inward direction. When a horizontal course of units has been mounted and held by the strips I9, a superimposed horizontal course 23 or layer of building units is placed and similarly held in position. The upwardly projecting contour of the strip I9 is such as to assist in guiding and supporting the upper course 23 of units and also to assist in crowding such units against the support 6 when a strip corresponding to strip I9 is placed upon them and nailed in position. In this fashion an entire surface is applied to a support 6 in a permanent and accurately aligned but nevertheless simple manner which can be effectuated by any ordinary workman.

As a final step, the space between the metal sheet II and the enameled metal sheet 24 of the unit 23 is sealed by a mastic 26 which is forced into position so as to enter into all of the adjacent interstices, as shown in Fig. 2, not only to seal between the metal edges but also against the insulating sheets and against the wooden strips I9. The strip I9 is preferably chamfered, as at 30, so that the mastic interlocks behind the edges of the sheets 9.

The form of the groove I1 and of the strip I9 can of course be varied in cross-section, and the strip I9, although successfully fabricated of wood, can as readily be a hollow metal tube or a solid metal member, without materially affecting the construction or mode of operation of my invention.

If the building unit is to be applied to a brick wall, for example, as shown in Fig. 4, I preferably place the composite sheet 3| in Contact with the brick support 32 and at a convenient or suitable place provide a fastening such as a hook 33, one end of which engages a depression 34 in the insulating sheet 36 of the unit 3I and the other end of which is enlarged to provide a head 31 embedded in mortar or concrete 38. If desired, a finishing channel 39 can be placed over the top of the unit 3| and can be embedded in the mortar or concrete. An appropriate finished surface 4I is made by troweling the mortar or concrete. An attractive and firm anchorage is thus provided for the supercially applied building unit.

In certain instances it may be desirable, by a direct metallic connection, to preclude separation between the metal enameled sheet of the building unit and the support. Under such circumstances, I preferably adopt a construction as disclosed in Fig. 5, in which the metal enameled sheet 46 is adhesively and compressively secured to a backing material 41 of insulating board or comparable substance. A metal hook 48 is welded in place, as at 49, and extends through a suitable passage 5I in the insulating material to a hook end 52 embedded in the concrete 53 or comparable material of the support. A suitable weather-sealing material, such as mastic or paint 54, is applied to the otherwise exposed edges of the enameled metal sheet 46. With this arrangement, the composite unit can be utilized as a mold or form when the concrete 53 is poured to make the wall 53 and embed the hook 52.

As another type of construction, I can provide the arrangement shown in Figs. 6, 7 and 8, in which I preferably provide an inverted metal angle 6I on a supporting floor 62 and to the angle at appropriate intervals fasten, as by welding 63, a plurality of upright angles 64, 66 and 61, all preferably facing in the same general direction. To seal or close the spaces between the sundry vertical angles, I preferably interpose between each of them a plurality of building units each comprised of a central sheet 68 of thermal insulating material, to the opposite sides of which have been xed adhesively and by compression enameled metal sheets 69 and 1I. The sheets are somewhat less in dimensions than the central material 68 which is provided on its marginal edges with nonplanar irregularities, such as grooves 12 and ridges 13 adapted to nest therewith. Preferably, the grooves 12 are provided on two adjacent sides of each of the units 68, while the ridges 'I3 are provided on the remaining two sides of the unit.

Each unit is interposed between a pair of the uprights, such as 64 .and 66, and is forced downwardly to rest upon the lower support angle 6I. As soon as a horizontal course hastbeen laid, a superposed course of inverted angles 16 is disposed between successive vertical angles 64, 66 and 61, for example, and is welded, as at 11 and 18, to hold the previously positioned units. Another horizontal course or layer of building units is then disposed between the angles 64, 66 and 61, and is in turn held in place by angles, similar to angles 16, welded in place. This construction provides a very thin wall which is excellent in appearance from opposite sides, is a good thermal insulator, is resistant to disintegration (particularly when the otherwise exposed edges of the angles 64 are masked either by mastic 8| or by clip strips 82), and is capable of Withstanding considerable loading from all directions.

Although described as a wall or vertical panel, the arrangement of Figs. 6, '7 and 8 is equally feasible as a floor, ceiling or horizontal panel.

As disclosed in Fig. 9, the support 86 is abutted by an adjacent pair of units 81 and 88, each of which is marginally grooved to provide a channel 89 inclined on one side and straight on the other side. Within the space so formed a structural shape, such as an angle iron 9|, is disposed, and a fastener 92 passes through the angle and engages the support 86. When the support 86 is wood, the fastener is preferably a screw, and when, the support 86 is masonry, a lag bolt and expansion shield are used. When the support is metal, the fastener is preferably a bolt or machine screw, or the angle 9| is directly Welded to the support 86. vA filling 93 of mastic seals the joint and completes the fabrication of the construction.

If for any reason it is deemed inadvisable to rely solely upon adhesion. between the enameled surface sheet and the insulating backing, the arrangement of Figs. 10, 11 and 12 is indicated. There is first formed a flat metal sheet generally rectangular in contour but having two opposite edges |02 and |03 turned to provide flanges. The contour of the flanges is such as to dene grooves |04 and |06, respectively, similar in shape to the grooves in the sheets 9, for example. An enamel surface is fused upon this sheet in the customary way, apertures |01 in the sheet facilitating the fusing operation by reducing the tendency to warp and distort.

Since the flanges are on only two opposite sides of the sheet |0|, a suitably grooved insulating backing |08 can be slipped into place between them and is held by mechanical interengagement. If desired, additional connection may be had by an adhesive between the sheets |0| and |08 and the assembly can be compressed as previously described, slight distortions of the flanges being immaterial or possibly beneficial.

The assembly is applied to a support |09 by an angle iron similar to the angle 9| (Fig. 9) held in place by any suitable fastener ||2 engaging the support. A filling of mastic ||3 seals the joint and interlocks with the apertures |01. Since the angle iron is in direct engagement with the re-entrant grooves |04 and |06 which preferably are horizontally disposed at the top and bottom of a unit in a vertical wall, the presence or absence of an adhesive between the sheets |0| and |08 does not affect the permanence or stability of the assembly.

I claim:

1. A building construction unit comprising an enameled stiff metal sheet of predetermined dimensions, and a compressed sheet of insulating material of larger dimensions adhesively united to said sheet and providing a margin therearound.

2. A building construction unit comprising a sheet of backing material having grooves in at least some of the edges thereof, and a stiff sheet of enameled metal secured to said backing sheet and stopping short of the edges thereof.

3. A building construction comprising a support, a sheet of backing material abutting said support, a stiff sheet of enameled metal secured to said backing sheet and stopping short of the edges thereof, and means engaging said backing sheet and said support for holding said metal sheet with respect to said support.

4. A building construction comprising a support, a pair of marginally grooved backing sheets abutting said support, a stiff sheet of enameled metal secured to each of said backing sheets and stopping short of the edges thereof, means interengaging said backing sheets in said grooves and fastened to said support, and a sealing means disposed between said metal sheets and overlying said interengaging means.

5. A building construction comprising a horizontal vstrip of nonplanar cross-section, a pair of backing sheets disposed on opposite sides of said strip and having marginal cross-sections adapted substantially to abut and interengage said strip, a stiff sheet of enameled metal secured to each of said backing sheets and stopping short of the edges thereof, said metal sheets being disposed in close proximity to each other, and means overlying the edges of said metal sheets and said strip to act as a mask therefor.

' HENRY G. I-IAUCI-I. 

